Mining

Transformer solutions in the mining industry need to adapt to the special requirements of high load, harsh environment and safety regulations, covering the entire process of open-pit mines, underground mines, and mineral processing plants. The following are key application scenarios and technical solutions for the mining industry:

Ⅰ. Core solutions for mining

1. Open-pit mine power supply system

- Mobile substation: with detachable transformer, it supports dynamic expansion of mining area and withstands mechanical shock of frequent relocation.

- High overload capacity design: to cope with instantaneous impact current of heavy equipment such as electric shovels and drilling rigs, forced air cooling or liquid cooling is adopted.

- Case: Chilean copper mine uses mobile oil-immersed transformer with protection level IP55, which can adapt to the high altitude and low pressure environment of the Andes Mountains.

2. Safe power supply for underground mines

- Explosion-proof mining transformer: Complies with IEC 60079 standard, adopts epoxy resin cast dry design to prevent methane or coal dust explosion.

- Low height and compactness: Adapt to the space limitations of the tunnel, design flat box, built-in moisture-proof heater to cope with high humidity underground.

Ⅱ. Ore processing and mineral processing

1. Crushing and grinding system

- Harmonic suppression technology: Multi-winding isolation transformers are configured for the variable frequency drive of ball mills and crushers to suppress 5/7/11 harmonics.

- Dynamic reactive power compensation: Integrated on-load voltage regulation to compensate for voltage drops caused by impact loads.

2. Flotation and smelting power supply

- Corrosion-resistant design: For acidic solution environments, stainless steel shells and silicone rubber seals are used to withstand chemical corrosion of pH 2-10.

- High temperature tolerance: The transformer supporting the smelting furnace uses H-class insulation material and a water-cooled heat dissipation system.

Ⅲ. Customized solutions for special scenarios

1. High-voltage power distribution in deep mines

- High mechanical strength design: Tolerant to the vibration of the shaft hoisting system, with elastic mounting base and seismic winding fixing structure.

- DC power supply system: Provide long-distance stable power supply for deep-well equipment through transformers.

2. Adaptation for extremely cold/high-temperature mining areas

- Low-temperature start-up solution: Use low-temperature silicon steel sheets and antifreeze insulating oil in -40℃ environment, and the preheating system ensures cold start reliability.

- Heat dissipation optimization in desert mining areas: Fully sealed design to prevent sand and dust, equipped with self-cleaning heat sink and high-temperature resistant windings.

IV. Intelligence and reliability improvement

1. Harsh environment monitoring system

- Dust and explosion-proof sensors: Real-time monitoring of winding temperature, partial discharge and insulation status, data uploaded to the control center through the mine intrinsically safe communication network.

- Edge computing fault diagnosis: Deploy AI algorithms in underground explosion-proof boxes to identify early insulation degradation and issue warnings.

2. Predictive maintenance and remote operation and maintenance

- Digital twin model: Combined with mining equipment operation data, simulate the transformer life attenuation curve and optimize the maintenance cycle.

AR remote collaboration: Use head-mounted devices to guide on-site personnel to quickly replace faulty parts.

V. Green and efficient transformation

1. New energy microgrid integration

- Photovoltaic storage and charging integration: Design amorphous alloy transformers for off-grid mining areas, compatible with the fluctuating power supply of photovoltaic + energy storage systems.

- Energy recovery system: Use the potential energy of ore conveyor belts to generate electricity, and use a bidirectional transformer to realize power feedback to the grid.

2. Application of environmentally friendly materials

- Biodegradable insulating oil: Use natural ester insulating fluid to replace mineral oil to reduce the risk of leakage pollution.

- Switchless equipment: Use vacuum arc extinguishing technology to avoid greenhouse gas emissions.

VI. Decommissioning and resource utilization

1. Harsh environment equipment regeneration

- Insulating oil purification technology: restore the performance of aged oil products through centrifugal separation and adsorption filtration.

- Modular remanufacturing: For retired transformers underground, replace moisture-resistant windings and casings to extend the service life by more than 15 years.

Summary

Mining transformers need to focus on the three core needs of explosion-proof safety, environmental tolerance, and high efficiency and reliability. The direction of technological evolution includes:

- Intelligence: AI-driven health management system and digital twin technology;

- Green: bio-based insulation materials and new energy microgrid adaptation design;

- Extreme environment adaptation: -50℃ to +60℃ wide temperature range operation, strong earthquake resistance and high altitude solutions.

The future trend will be to combine the power supply needs of automated mining equipment, develop high dynamic response transformers, and deepen the integration and application with 5G and the Internet of Things.